TASK 72-31-11-300-032 LPC Fan Blade - Repair The Metal Spray Coating (Metco 58NS) On The Dovetail Root Flanks, Repair-032 (VRS1067)

DMC:V2500-A0-72-31-1101-00A-609A-C|Issue No:001.00|Issue Date:2014-05-01

Export Control

EAR Export Classification: Not subject to the EAR per 15 C.F.R. Chapter 1, Part 734.3(b)(3), except for the following Service Bulletins which are currently published as EAR Export Classification 9E991: SBE70-0992, SBE72-0483, SBE72-0580, SBE72-0588, SBE72-0640, SBE73-0209, SBE80-0024 and SBE80-0025.

Copyright

© IAE International Aero Engines AG (2001, 2014 - 2021) The information contained in this document is the property of © IAE International Aero Engines AG and may not be copied or used for any purpose other than that for which it is supplied without the express written authority of © IAE International Aero Engines AG. (This does not preclude use by engine and aircraft operators for normal instructional, maintenance or overhaul purposes.).

Applicability

All

Common Information

TASK 72-31-11-300-032 LPC Fan Blade - Repair The Metal Spray Coating (Metco 58NS) On The Dovetail Root Flanks, Repair-032 (VRS1067)

Effectivity

FIG/ITEM

PART NO.

01-300

6A7649

01-300

6A7650

01-300

6A7651

01-300

6A7652

01-300

6A7653

01-300

6A7658

01-300

6A7654

01-300

6A7655

01-300

6A7614

01-300

6A7613

General

This repair removes and replaces the metal spray coating (Metco 58NS) on the dovetail root flanks of the Low Pressure (LP) Compressor Rotor Blade.

Source demonstration is necessary for this repair and can only be done by approved vendors.

This Repair must only be done when the instruction to do so is given in 72-31-11 Inspection/Check, but may also be used in conjunction with SB V2500-ENG-72-0384 during the rework of service run blades for the first time application of the metal spray coating.

When CoMat 03-261 METAL SPRAY POWDER, Cu,Ni, In is referenced, only Metco 58NS may be used. Alternatives or equivalents to Metco 58NS must not be used.

The practices and processes referred to in the procedure by the TASK/SUBTASK numbers are in the SPM.

The blade root must be abrasive blasted prior to application of Metco 58NS.

The blade root must not be abrasive blasted more than two times without the root being shot peened in accordance with VRS1723.

The blade root can only be shot peened in accordance with VRS1723 a maximum of four times.

Repair Facilities

The source demonstration requirements of this repair means that any facility not authorized to accomplish this repair either, utilize the authorized repair vendors listed below or contact the IAE repair services group to determine if a qualification program can be initiated at their facility.

IAE - INTERNATIONAL AERO ENGINES AG
C/O ROLLS-ROYCE PLC
P.O. BOX 31
DERBY DE24 8BJ
ENGLAND
ATTN: MANAGER TECHNICAL SERVICES
Authorized repair vendors for repair VRS1067 are listed below:
SERMATECH REPAIR SERVICES LTD
HIGH HOLBORN ROAD
CODNOR 
RIPLEY
DERBYSHIRE
DE5 3NW
ENGLAND
GKN AEROSPACE CHEM-TRONICS INC
1150 WEST BRADLEY
EL CAJON
CA 92020
USA
HONG KONG AERO ENGINE SERVICES LIMITED (HAESL)
70 CHUN CHOI STREET
TSEUNG KWAN O INDUSTRIAL ESTATE
TSEUNG KWAN O
NEW TERRITORIES
HONG KONG
ROLLS ROYCE PLC
AERO REPAIR AND OVERHAUL
MAVOR AVENUE
NERSTON
EAST KILBRIDE
GLASGOW G74 4PY
SCOTLAND
MTU MAINTENANCE GMBH
FLUGHAFEN HANNOVER
MUNCHER STRASSE 31
30855 LANGENHAGEN
GERMANY
IHI corporation
229 TONOGAYA MIZUHO-MACHI
NISHITAMA-GUN,
TOKYO 190-1297
JAPAN
ATTN: CUSTOMER SUPPORT MANAGER, MAINTENANCE DEPARTMENT, CIVIL AERO-ENGINE DIVISION, AERO-ENGINE AND SPACE OPERATIONS
Tel: 81-42-568-7362
Fax: 81-42-568-7566
LUFTHANSA TECHNIK AG
PRODUCT SALES EPAR (ENGINE PARTS AND ACCESSORIES REPAIR)
HAM WR1
WEG BEIM JAGER 193
22335 HAMBURG
GERMANY
NOTE
More equipment and materials necessary to do this Repair are in the SPM TASKS.
NOTE
To identify the consumable materials, refer to the PCI.
NOTE
Special tools are indentified in the procedure by the tool primary number.
Preliminary Requirements
Pre-Conditions
NONE
Support Equipment
NameManufacturerPart Number / IdentificationQuantityRemark
Abrasive blast equipmentLOCALAbrasive blast equipment
Chemical strip equipmentLOCALChemical strip equipment
Metal spray equipmentLOCALMetal spray equipment
Penetrant Crack Test EquipmentLOCALPenetrant crack test equipment
Vibration peen equipmentLOCALVibration peen equipment
Workshop inspection equipmentLOCALWorkshop inspection equipment
IAE 3R19551 Metal Spray Fixture0AM53IAE 3R195511
IAE 3R19454 Binocular Inspection Fixture0AM53IAE 3R194541
Consumables, Materials and Expendables
NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 03-261 METAL SPRAY POWDER, Cu,Ni, InK1030CoMat 03-261
CoMat 05-022 ALUMINUM OXIDE ABRASIVE62596CoMat 05-022
CoMat 06-022 FLUORESCENT PENETRANT (POST-EMULSIFIED ULTRA HIGH SENSITIVITY)LOCALCoMat 06-022
CoMat 05-002 ABRASIVE MEDIUM, ALUMINUM OXIDELOCALCoMat 05-002
Spares
NONE
Safety Requirements
NONE
Procedure
    1. SUBTASK 72-31-11-220-146 Visually Examine Blade Markings
      1. NOTE
        The initial application of Metco 58 in accordance with SB 72-0375 or SB 72-0384 is to be considered to be the first application of abrasive blasting (i.e. VRS1067/1).
        Where VRS1067/2 is identified, the blade root must be shot peened.
        Examine the blade markings for previous applications of this repair.
      1. Marked 'VRS1067/1' - Previously shot peened and abrasive blasted.
        Marked 'VRS1067/2' - Previously Abrasive blasted only.
    2. SUBTASK 72-31-11-350-108 Remove the Chocking Pads and Dry Film Lubricant
    1. Refer to Figure
      2. Remove existing choking pads and dry film lubricant as necessary.
        1. Refer to VRS1022, TASK 72-31-11-300-009 (REPAIR-009).
        1. Refer to VRS1028, TASK 72-31-11-300-013 (REPAIR-013).
        2. Refer to VRS1021, TASK 72-31-11-300-011 (REPAIR-011).
        3. Refer to VRS1023, TASK 72-31-11-300-021 (REPAIR-021).
    3. SUBTASK 72-31-11-330-002 Remove the Metal Spray Coating from the Blade
    1. Refer to Figure and Figure
      2. NOTE
        Do not abrasive blast to remove any remaining coating. For Nitric Acid Strip - corrosion protection and final de-embrittlement, heat treat is not required.
        For Cyanide Strip - corrosion protection is not required.
        Remove the coating from the blade dovetail root flanks.
        1. Refer to the SPM TASK 70-33-59-300-503, SUBTASK 70-33-59-300-001 (prepare the parts) and SUBTASK 70-33-59-300-002 (Nitric Acid Strip) or SUBTASK 70-33-59-300-004 (Cyanide Strip).
        1. Use chemical stripping equipment.
    4. SUBTASK 72-31-11-230-075 Do the Ultrasonically Inspection both Flanks of the Blade Root
      1. NOTE
        Make sure both concave and convex flanks are examined.
        Reject if cracked or scarred.
        Ultrasonically examine both the blade root flanks.
      1. Refer to the SPM TASK 72-00-00-200-000 (INSPECTION/CHECK).
    5. SUBTASK 72-31-11-230-076 Do the Fluorescent Penetrant Inspection
      1. Do a penetrant crack test on the repair area.
        1. Refer to the SPM TASK 70-23-04-230-501.
        1. Use CoMat 06-022 FLUORESCENT PENETRANT (POST-EMULSIFIED ULTRA HIGH SENSITIVITY) ultra high sensitivity post emulsified fluorescent penetrant.
        2. Reject if cracked or scarred.
        3. Use penetrant crack test equipment.
    6. SUBTASK 72-31-11-220-147 Visually Examine the Blade Root
      1. Visually examine the blade root for damage.
      1. Visually examine the blade root for damage.
      2. Reject if cracked or scarred.
    7. SUBTASK 72-31-11-380-059 Shot Peen the Dovetail Root
    1. Refer to Figure and Figure.
      2. NOTE
        If the blade is marked with 'VRS1067/2' then it must be shot peened.
        Shot peen the dovetail root if necessary.
      1. Refer to VRS1723, TASK 72-31-11-300-024 (REPAIR-024).
    8. SUBTASK 72-31-11-350-109 Mask the Blade
      1. NOTE
        It is important to make sure the correct positioning of the masking tape.
        Mask the blade.
      1. Refer to SPM TASK 70-34-01-340-001.
      2. Put suitable masking tape on the areas not to be abrasive blasted and metal sprayed.
    9. SUBTASK 72-31-11-120-053 Clean the Blade
    1. Refer to Figure and Figure.
      2. Abrasive blast the blade.
        1. Refer to SPM TASK 70-34-01-340-001.
        1. Abrasive blast area to be metal sprayed at 20 to 25 p.s.i. using pressure pot abrasive blasting equipment.
        2. Keep a nozzle to part distance of at least 76 millimetres (3 inches).
        3. Make sure that the blasting cabinet is thoroughly cleaned and the abrasive medium is changed before blasting each set of fanblades (22 off).
        5. Use abrasive blasting equipment.
    10. SUBTASK 72-31-11-340-001 Renew Blade Masking
    1. Refer to: Figure and Figure
      2. NOTE
        It is important to make sure the correct positioning of the masking tape.
        Renew blade masking if necessary.
        1. Refer to SPM TASK 70-34-01-340-001.
        1. Renew the masking on the areas not to be metal sprayed as necessary.
        2. Take care not to touch the prepared surfaces.
    11. SUBTASK 72-31-11-340-002 Metal Spray the Blade
    1. Refer to Figure and Figure
      2. Apply the metal spray to the dovetail root flanks.
        1. Refer to the SPM TASK 70-34-01-340-501 SUBTASK 70-34-01-340-005.
        1. Use CoMat 03-261 METAL SPRAY POWDER, Cu,Ni, In (Metco 58NS) metal spray powder - copper, nickel, indium.
        2. Apply the metal spray to areas designated 'C'.
        3. Overspray is permitted within areas 'D'.
        4. Alternatives or equivalents to Metco 58NS must not be used.
        5. Apply the metal spray to a thickness of 0.0039 to 0.0059 in (0.10 to 0.15mm) and leave in the 'as sprayed' condition. Use approved metal spray fixture and test piece holder - 1 off.
        6. Use metal spray equipment.
    12. SUBTASK 72-31-11-340-003 Remove the Blade Masking
      1. Remove the blade masking.
      1. Take care not to damage the sprayed coating. Use hand methods.
    13. SUBTASK 72-31-11-350-110 Do an Inspection of the Metal Sprayed Coating
    1. Refer to Figure and Figure.
      2. Do an inspection of the metal sprayed coating.
        1. Refer to the SPM TASK 70-34-01-340-501, SUBTASK 70-34-01-340-005.
        1. Make sure the metal sprayed coating has been correctly applied. Make sure the thickness of the sprayed coating is within the limits given by measuring the coating thickness on the metal spray test pieces.
        2. If the thickness of the metal spray is outside the limits, the blade must be rejected.
        3. Use inspection equipment.
    14. SUBTASK 72-31-11-380-060 Replace the Dry Film Lubricant
    1. Refer to Figure
      2. Replace the dry film lubricant.
      1. Refer to VRS1021, TASK 72-31-11-300-011 (REPAIR-011) or refer to VRS1023, TASK 72-31-11-300-021 (REPAIR-021).
    15. SUBTASK 72-31-11-320-001 Replace the Chocking Pads
    1. Refer to: Figure
      2. Replace the chocking pads.
      1. Refer to VRS1028, TASK 72-31-11-300-013 (REPAIR-013) or refer to VRS1022, TASK 72-31-11-300-009 (REPAIR-009).
    16. SUBTASK 72-31-11-350-111 Identify the Repair
      1. NOTE
        The initial application of Metco 58 in accordance with SB72-0375 or SB72-0384 is to be considered to be the first application of abrasive blasting (i.e. VRS1067/1).
        Identify the repair by vibration peening adjacent to the part number.
      1. If the blade root has been shot peened and abrasive blasted during the accomplishment of this repair then mark 'VRS1067/1'.
      2. If the blade root has been abrasive blasted only during the accomplishment of this repair then mark 'VRS1067/2' and put a single line through previous marking.
      3. Use vibration peen equipment.
    17. Figure: Repair Details and Dimensions
    Repair Details and Dimensions
    Figure: Repair Details and Dimensions
    Repair Details and Dimensions
    Figure: Repair Details and Dimensions
    Repair Details and Dimensions
Requirements After Job Completion
Follow-On Conditions
NONE
Manufacturer Code:0AM53
Enterprise Name:IAE INTERNATIONAL AERO ENGINES AG
BU Name:NULL
Building:SUITE 400
Street:628 HEBRON AVENUE
City:GLASTONBURY
State:CT
Zip Code:06033
Country:USA
Manufacturer Code:62596
Enterprise Name:MICRO ABRASIVES CORPORATION
BU Name:MICRO ABRASIVES CORPORATION
Street:720 SOUTHAMPTON RD
P.O. Box:669
City:WESTFIELD
State:MA
Zip Code:01085-0669
Country:USA
Phone Number:1-413-562-3641
Fax Number:1-413-562-7409
Internet:www.microgrit.com
Manufacturer Code:K1030
Enterprise Name:DELETED
BU Name:DELETED,SEE CAGE CODE K1030
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:K1030
Supply Number:CoMat 03-261
Type:sp01
Supply Short Name:CoMat 03-261 METAL SPRAY POWDER, Cu, Ni, In
Supply Name:CoMat 03-261 METAL SPRAY POWDER, Cu,Ni, In
Specification Groups:
Doc NumberType
METCO 58-NS MSRR9507/31OMAT:328(RR REF)
METCO 58-NSOMAT:328
Suppliers:
ManufacturerRemarks
K1030
Manufacturer Code:X222X
Supply Number:CoMat 05-002
Type:sp01
Supply Short Name:CoMat 05-002 ABRASIVE MEDIUM, ALUMINUM OXIDE
Supply Name:CoMat 05-002 ABRASIVE MEDIUM, ALUMINUM OXIDE
Specification Groups:
Doc NumberType
Where CoMat 05-002 is specified with no letter suffix, use one of the CoMat 05-002 letter suffix alternatives.
Suppliers:
ManufacturerRemarks
X222X
Manufacturer Code:62596
Supply Number:CoMat 05-022
Type:sp01
Supply Short Name:CoMat 05-022 ALUMINUM OXIDE ABRASIVE
Supply Name:CoMat 05-022 ALUMINUM OXIDE ABRASIVE
Specification Groups:
Doc NumberType
PMC 3046ALUMINUM OXIDE No. 240
Suppliers:
ManufacturerRemarks
62596
Manufacturer Code:X222X
Supply Number:CoMat 06-022
Type:sp01
Supply Short Name:CoMat 06-022 FLUORESCENT PENETRANT (POST-EMULSIFIED ULTRA HIGH SENSITIVITY)
Supply Name:CoMat 06-022 FLUORESCENT PENETRANT (POST-EMULSIFIED ULTRA HIGH SENSITIVITY)
Specification Groups:
Doc NumberType
ARDROX 985-P14 OMAT: 652 (CHEMETALL OAKITE 985-P14)It is not permitted to mix the selected CoMat 06‐022 letter suffix material with other CoMat 06‐022 letter suffix materials. Where CoMat 06‐022 is specified with no suffix, use one of the CoMat 06‐ 022 letter suffix materials. 
Suppliers:
ManufacturerRemarks
X222X
Link not Found
Manufacturer Code:LOCAL
Tool Number:Chemical strip equipment
Tool Name:Chemical strip equipment
Manufacturer Code:0AM53
Tool Number:IAE 3R19454
Tool Name:IAE 3R19454 Binocular Inspection Fixture
Manufacturer Code:0AM53
Tool Number:IAE 3R19551
Tool Name:IAE 3R19551 Metal Spray Fixture
Manufacturer Code:LOCAL
Tool Number:Metal spray equipment
Tool Name:Metal spray equipment
Manufacturer Code:LOCAL
Tool Number:Penetrant crack test equipment
Tool Name:Penetrant Crack Test Equipment
Manufacturer Code:LOCAL
Tool Number:Vibration peen equipment
Tool Name:Vibration peen equipment
Manufacturer Code:LOCAL
Tool Number:Workshop inspection equipment
Tool Name:Workshop inspection equipment